Sudhakar "Bob" Chaphalkar

**** ********** ******

Lansing, Michigan 48912

517-***-**** home

517-***-**** mobile

abl6u0@r.postjobfree.com

http://www.linkedin.com/pub/bob-chaphalkar/8/4b3/8

EDUCATION

B.S. in Electrical Engineering, 1973

Detroit Institute of Technology, Detroit, Michigan

Coursework in Electrical Engineering, 1968 to 1972

Michigan State University, East Lansing, Michigan

B.S. in Physics, Chemistry & Mathematics, 1968

Marathwada University, Aurangabad, India

A.A. in Photography, 2011 (expected)

Lansing Community College, Lansing, Michigan

Fluency in English, Marathi and Hindi

EXPERIENCE

Senior Controls/Electrical Engineer

2005 to 2009

Control System Integrators Inc., Lansing, Michigan

Debug and start up ControlLogix based systems. Program, start up and debug

PowerFlex drives; debug ControlNet, DeviceNet and EtherNet/IP networks

installed on five new FedEx "Next Gen (sortation) hub" sites. Develop

standards for design and design reviews. Develop procedures for various

engineering functions. Consulting for the following companies:

Industrial Machine Products (IMPCO), Lansing, Michigan

Design and develop control systems for Micro finishing machines for

major automotive companies. Specify, design and layout electrical

control (equipment) for dedicated Micro polishers for automotive.

Utilize and integrate new MMI hardware and PLCs. Provide complete

system design. Work with shop floor personnel to commission the job.

Manage projects as required by IMPCO.

.

RDS Engineering and Jacobs Engineering, Battle Creek, Michigan

Manage Electrical Controls projects for Kellogg's Company. Specify,

design and layout electrical control (equipment) for process control

equipment such as mixers, blenders, conveyors and scales. Research new

MMI, hardware and software, new and advanced PLCs. Provide complete

system design. Debug and run the above equipment on the shop floor.

Manage projects as required by Kellogg's.

Controls Manager/Senior Electrical Engineer

2002 to 2005

Automated Process Equipment Corporation, Lake Odessa, Michigan

Manage Electrical Controls Department. Specify, design and program complete

electrical control equipment for process control equipment such as mixers,

blenders, conveyors, scales, weigh screw conveyors, Micro Ingredient

Scales. Research new MMI hardware and software, new and advanced PLCs.

Designed custom heater controls for the mixer coater equipment. Provide

complete system design. Debug and run the above equipment on the shop

floor. Manage projects as required by the customer.

Designed Control Equipment using the following PLCs: Allen-Bradley

(all types and sizes except PLC-3)

Designed Equipment using the following MMIs: Allen-Bradley PanelView

550, PanelView 300, and RSView32

Self-Initiated Energy Saving Project: Recommended that we turn off all

office equipment through most weekends for energy savings saving the

company at least $2,000 per year and extended life of the equipment by

three years. Total estimated savings over next three years: $6,000

Senior Designer/Controls Engineer

2000 to 2002

Eckhart & Associates, Lansing, Michigan

Specify, design and program complete electrical control equipment for a

turnkey operation. This includes: articulating arms, conveyors, presses,

and machines, test equipment, interfaces to other units such as

robots/gantries etc. Specify and design hydraulic & pneumatic controls for

the above items. Debug and run the above equipment. Manage projects as

required by the customer.

Designed Control Equipment using the following PLCs: Telemecanique,

Allen-Bradley (all types and sizes except PLC-3)

Designed Equipment using the following MMIs: Allen-Bradley PanelView

550

Self-Initiated Energy Saving Project: Reconfigured and reprogrammed

the shop air compressor to save at least $2,000 per year and extended

life of the equipment by ten years. Total estimated savings over ten

years: $22,000

Senior Designer/Engineer

1986 to 2000

Cummings Industrial Systems, Lansing, Michigan

Specify, design and program complete electrical control equipment for a

turnkey operation. This includes: conveyors, presses, and machines, test

equipment, interfaces to other units such as robots/gantries etc. Specify

and design hydraulic & pneumatic controls for the above items. Debug and

run the above equipment. Manage projects as required by the customer.

Designed Control Equipment using the following PLCs: Honeywell 635,

Allen-Bradley (all types and sizes except PLC-3); Square-D Series 600

and 400; Modicon 484, 584, 984-680; GE Series-1; Mitsubishi F and A

Series

Designed Control Equipment using the following Drives: Allen-Bradley

1305, 1336 plus; Square-D Altivar

Designed Equipment using the following MMIs: Allen-Bradley PanelView

550, PanelView 1200; IDT Panelmate (all models)

Examples of Major Projects:

GM: SMCO/ GMPT (Saginaw, Michigan): "Andon" display systems for Green

Aluminum Machining area, South Core Room, Cupola and Charger system

for iron melting operations: completely reengineer the above systems

for a turnkey solution.

GM LAD (Lansing, Michigan): Design and implement energy management

system for building 90.

GM Kalamazoo (Kalamazoo, Michigan): Design and implement press

automation and interface to robots between the presses.

GM Cadillac (Grand Blanc, Michigan): Press automation, welding nests

etc.

FORD (Dearborn, Michigan): Six PLC 5/40s controlling presses,

interfaced with five FANUC robots and a main PLC 5/60 supervisor;

automatic shut height changes based on data tables entered into A-B

PanelView 1200s. Start up and debug

Allied Signal Bendix BOSCH: Retrofit new controls for a 22 station and

for a 24-station transfer line; with each station on a remote I/O and

almost each spindle on a 1336 plus drive. Start up and debug

Diamond Star Motors (Mitsubishi): Interface Mitsubishi PLC to twin

FANUC robots to apply rear quarter glass and primer to car (Eclipse)

on the assembly line

Universal Electric (now Magnetek), Owosso, Michigan

Project Engineer, Research & Development

1983 to 1985

Designed, developed, tested and analyzed fractional hp electric

motors. Designed laminations, windings and other electrical and

mechanical components. Examples of typical assignments are shown

below:

. Design of a high efficiency electric motor for the 8-pole

fan market. Savings of $1.20 per motor

. Investigation of a capacitor problem: savings of $35,500

. Improvement of brush life: Continuation of performance

improvement

. Design new laminations for a small motor: Entry into a

2,000,000 motors per year market

. Elimination, modification & improvement of Test equipment for

R&D

Process Control Equipment Manager

1982 to 1983

Designed, developed and built process control equipment. Specified and

purchased control and test equipment. Supervised 3 electronic

technicians in this activity. Examples of typical assignments are

shown below:

. Standardization of all process control equipment

. Standardization and documentation of all "production processes

used in all four plants

. Reduce excessive Flash on Rotors

. Improvement of Quality Standardization of Varnish Process

. Introduction of Test Standards and Process standards

. Quality charts for various processes: Quality of Fields, rotors,

varnish etc

Test Equipment Manager

1978 to 1982

. Standardization of "HIPOT" Equipment

. Torque Test Equipment for Die Cast Rotors (aluminum)

. Equipment modernization of pump test equipment line

. Update of Test procedures on motors

. Employee Training: Motor Theory Classes for all hourly employees

. Test equipment - "Quality of Fields"

. Submersible Pump Motor Test Equipment

A/V Technician

1973 to 1978

Instructional Media Center, Michigan State University, East Lansing,

Michigan

Troubleshoot, repair, tune and upgrade various types of audio/visual

equipment. Support all academic sessions, cultural events and sports events

on and off campus, including set-up, operation and take-down

Faculty Assistant in Electrical Engineering

1972 to 1973

Detroit institute of Technology, Detroit, Michigan

Assist professors and lab personnel in the Electrical Engineering

department, tutor freshmen students in Electrical Engineering

INTERESTS

Photography: Nature, Commercial & portrait photography.

Electronics: Learning and experimenting with new microcontrollers and

sensors and gadgets

Sports: Golf, Bicycling

Philosophy, art

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